Overhead and gantry crane definitions

Under 1910.179(a)(1) a crane is a machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine. This includes cranes that are fixed or mobile and that are driven manually or by power. See Definition in 1910.179(a)(1).

• Practical note: Common types covered by the standard include overhead cranes, gantry cranes, semigantry, cantilever gantry, wall cranes, and storage bridge cranes as listed throughout 1910.179.

Under 1910.179(a)(8) an overhead crane is a crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure, while under 1910.179(a)(6) a gantry crane is similar except its bridge is supported on legs that run on ground-level rails or runway. See Overhead crane definition 1910.179(a)(8) and Gantry crane definition 1910.179(a)(6).

• Practical difference: overhead cranes run on an elevated runway attached to the building; gantry cranes have supporting legs and often run at floor level on rails.

Under 1910.179(a)(50) "rated load" means the maximum load for which a crane or individual hoist is designed and built by the manufacturer and shown on the equipment nameplate(s). The rated load must be plainly marked on each side of the crane, and if there is more than one hoist each hoist or its load block must have its rated load marked legibly from the ground or floor per 1910.179(b)(5).

• Practical tip: Make sure nameplates and hoist markings are kept clean and readable; obscured ratings can create serious overload hazards.

Under 1910.179(b)(3) you must have any crane modifications and reratings checked thoroughly for the new rated load by a qualified engineer or the equipment manufacturer, and the crane must be tested in accordance with 1910.179(k)(2). The new rated load must also be displayed as required in 1910.179(b)(5).

• Practical steps: document the engineering review, perform the required proof test, update nameplates, and retain test records.

Under 1910.179(b)(6)(i) you must provide and maintain a minimum clearance of 3 inches overhead and 2 inches laterally between the crane and obstructions, in conformity with the referenced Crane Manufacturers Association specification.

• Practical note: Keep these clearances free of permanent or temporary obstructions (wiring, ductwork, shelving, etc.). If passageways or walkways exist, do not place obstructions where crane movement could jeopardize personnel safety per 1910.179(b)(6)(ii).

Under 1910.179(b)(7) you must provide and maintain adequate clearance between the bridges of two parallel cranes when there are no intervening walls or structures.

• Practical guidance: "Adequate clearance" means sufficient distance to avoid collision or pinching, allow safe passage of loads, and permit maintenance access; consult crane manufacturer or engineer for specific spacing in tight installations.

Under 1910.179(b)(8) only designated personnel are permitted to operate cranes covered by this section.

• Practical meaning: The employer must assign (appoint) specific employees who are trained and competent to operate the crane; casual or unauthorised employees must not be permitted to operate it.

Under 1910.179(c)(1)(i) the cab layout and controls must place all operating handles within convenient reach of the operator when facing the area to be served by the load hook or the direction of travel, and allow a full view of the load hook in all positions. Under 1910.179(c)(1)(ii) the cab must afford a minimum of 3 inches clearance from all fixed structures within its area of possible movement.

• Practical checklist: arrange controls ergonomically, ensure unobstructed hook sightlines, and verify the 3-inch movement clearance around the cab.

Under 1910.179(c)(2) access to the cab and bridge walkways must be by a conveniently placed fixed ladder, stairs, or platform, and there must be no step over any gap exceeding 12 inches (30 cm). Fixed ladders must comply with the requirements in 29 CFR part 1910 Subpart D.

• Practical point: Provide secure, code-compliant access (no makeshift ladders or step gaps) and inspect access devices regularly.

Under 1910.179(d)(1)(ii) footwalks must provide at least 48 inches of headroom. Under 1910.179(d)(2)(i) footwalks must be rigidly constructed and designed to sustain a distributed load of at least 50 pounds per square foot.

• Practical action: Verify footwalks meet these minimums and post signs or limit access if headroom/load limits are compromised by later installations.

New overhead and gantry cranes constructed and installed on or after August 31, 1971, must meet the design specifications of the American National Standard Safety Code for Overhead and Gantry Cranes, ANSI B30.2.0-1967, as incorporated by reference in 1910.179(b).

• Practical consequence: For new cranes installed after that date, use ANSI B30.2.0-1967 design practices and keep documentation showing compliance.

Under 1910.179(a)(59) an emergency stop switch is a manually or automatically operated electric switch that cuts off electric power independently of the regular operating controls.

• Practical use: Emergency stop switches should be accessible, clearly marked, and maintained to immediately isolate power in dangerous situations.

Under 1910.179(a)(36) a drift point is a point on a travel motion controller which releases the brake while the motor is not energized, allowing the crane to coast before the brake is set.

• Practical effect: Controllers with drift points allow smooth coasting motions but require maintenance and operator awareness to prevent unintended movement near obstructions or personnel.

Under 1910.179(a)(17) an auxiliary hoist is a supplemental hoisting unit of lighter capacity and usually higher speed than the main hoist; under 1910.179(a)(48) the main hoist is the hoist mechanism provided for lifting the maximum rated load.

• Practical guidance: Use the main hoist for heavy lifts at rated capacity; use the auxiliary for lighter, faster positioning tasks. Both must have their rated loads marked per 1910.179(b)(5).

Under 1910.179(a)(25) "clearance" means the distance from any part of the crane to the point of the nearest obstruction. Measure clearance from the furthest projecting point of the crane (including cab, hook, or other attachments) to the nearest fixed object or structure in the crane’s path of movement.

• Practical step: Verify clearances in all travel directions and maintain the minimums specified in 1910.179(b)(6)(i).

Under 1910.179(b)(4) outdoor storage bridge cranes must have automatic rail clamps and a wind-indicating device that provides a visible or audible alarm to the bridge operator at a predetermined wind velocity. If the clamps act on rail heads, any beads or weld flash on the rail heads must be ground off.

• Practical action: Install and maintain rail clamps and wind indicators and ensure rail heads are smooth where clamps engage.

Under 1910.179(a)(41) a footwalk is the walkway with handrail attached to the bridge or trolley for access. Under 1910.179(a)(31) "dynamic" refers to a method of controlling crane motor speeds when in the overhauling condition to provide a retarding force.

• Practical note: Footwalks provide safe access for inspection/maintenance; dynamic braking systems help control loads during lowering or overhauling conditions.

Under 1910.179(a)(65) a "truck" is the unit that supports bridge girders or trolleys, and under 1910.179(b)(1) the section applies to overhead and gantry cranes, including semigantry, cantilever gantry, wall cranes, storage bridge cranes, and others having the same fundamental characteristics (trolleys and similar travel).

• Practical implication: If your equipment has a bridge and trolley travel characteristics like those listed, it falls under 1910.179 and must follow the standard's requirements.

Yes — crane operators must wear head protection when there is potential for injury to the head from falling objects, including when lifting with cranes or hoists, as explained in OSHA’s interpretation "Head protection for crane operators" (June 6, 2024) available at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2. That interpretation references the head protection standard which requires compliance with ANSI Z89.1 consensus standards incorporated by reference in 29 CFR 1910.135 (see the interpretation for full details).

• Practical actions: Perform a hazard assessment under 29 CFR 1910.132(d)(1) (referenced in the interpretation), provide helmets meeting ANSI Z89.1 (e.g., 2009/2003/1997 editions), and require operators to avoid carrying loads over people as noted in the interpretation.

Under 1910.179(a)(12) a semigantry crane is a gantry crane with one end of the bridge rigidly supported on legs that run on a fixed rail or runway, while the other end is supported by a truck running on an elevated rail or runway. This differs from a full gantry crane (see 1910.179(a)(6)) where both ends of the bridge are supported on legs that run on ground-level rails.

• Practical consequence: Semigantry cranes combine building-supported and truck-supported ends, affecting runway design and support checks during modifications.

Yes — footwalks must have a walking surface of an antislip type, and wood is explicitly noted as acceptable. OSHA requires an antislip walking surface for crane footwalks under 1910.179(d)(2)(ii).

Yes — toeboards and handrails on crane footwalks must comply with OSHA’s general guard and railing rules in Subpart D. The standard requires that toeboards and handrails for footwalks comply with Subpart D of 29 CFR 1910 as stated in 1910.179(d)(3).

Yes — gantry cranes must be provided with ladders or stairways from the ground to the footwalk or cab platform. OSHA specifies this requirement in 1910.179(d)(4)(i).

Stairs must have rigid, substantial metal handrails and walking surfaces of an antislip type. OSHA requires stairways on cranes to be equipped with rigid metal handrails and antislip walking surfaces under 1910.179(d)(4)(ii).

Ladders must be permanently and securely fastened and constructed to comply with Subpart D ladder requirements. OSHA requires crane ladders to be permanently secured and built in accordance with Subpart D of 29 CFR 1910 as stated in 1910.179(d)(4)(iii).

Trolley stops must be provided at the trolley travel limits and fastened so they resist forces when contacted. OSHA requires stops at trolley limits of travel and that they be fastened to resist contact forces under 1910.179(e)(1)(i) and 1910.179(e)(1)(ii).

A stop that engages the wheel tread must be at least as high as the wheel radius. OSHA specifies that a stop engaging the wheel tread shall be of a height at least equal to the radius of the wheel in 1910.179(e)(1)(iii).

Bridge bumpers are required unless the crane operates so slowly or is restricted such that striking objects is not a hazard, and they must stop the crane (excluding the lifted load) with average deceleration not exceeding 3 ft/s² when traveling at 20% of rated load speed; they must also absorb energy to stop the crane at at least 40% of rated load speed. OSHA details these requirements for bridge bumpers in 1910.179(e)(2)(i) and the energy-absorption requirement in 1910.179(e)(2)(i)(a).

Bumpers must be mounted so there is no direct shear on bolts, and they must be designed and installed to minimize parts falling from the crane if they break. OSHA requires these mounting and design features in 1910.179(e)(2)(i)(b) and 1910.179(e)(2)(ii).

Each trolley must have bumpers (unless operating conditions make them unnecessary), and bumpers must stop the trolley (excluding the load) at an average deceleration not to exceed 4.7 ft/s² at one-third of rated load speed; when multiple trolleys operate on the same bridge, adjacent ends must have bumpers or equivalents. OSHA requires trolley bumpers and specifies performance and multi-trolley rules in 1910.179(e)(3)(i) and 1910.179(e)(3)(ii).

Rail sweeps are devices extending below the top of the rail and projecting in front of truck wheels, and bridge trucks must be equipped with them. OSHA requires bridge trucks to be equipped with rail sweeps that extend below rail tops and project in front of wheels in 1910.179(e)(4).

Guards must be installed if hoisting ropes run near other parts where fouling or chafing is possible, and a guard must prevent contact between bridge conductors and hoisting ropes if contact could occur. OSHA requires these guards in 1910.179(e)(5)(i) and 1910.179(e)(5)(ii).

Exposed moving parts that could be hazardous in normal operation (gears, set screws, keys, chains, sprockets, reciprocating parts) must be guarded; guards must be securely fastened and able to support the weight of a 200-pound person unless located where stepping on them is impossible. OSHA specifies these guarding and strength requirements in 1910.179(e)(6)(i), 1910.179(e)(6)(ii), and 1910.179(e)(6)(iii).

Each independent hoisting unit must have at least one self-setting holding brake applied directly to the motor shaft or gear train, and except for certain worm-geared hoists, must also have control braking means to prevent overspeed when lowering. OSHA requires these holding and control brakes in 1910.179(f)(1)(i) and 1910.179(f)(1)(ii).

Holding brakes for hoist motors must provide at least 125% of full-load hoisting torque when used with non-mechanical control braking, 100% when used with mechanical control braking, and 100% for each of two holding brakes if two are provided. OSHA sets these minimum torque percentages in 1910.179(f)(2)(i)(a), 1910.179(f)(2)(i)(b), and 1910.179(f)(2)(i)(c).

Holding brakes on hoists must apply automatically when power is removed, and where necessary they must have means for adjusting to compensate for wear. OSHA requires automatic application on power loss in 1910.179(f)(2)(iii) and adjustment means for wear in 1910.179(f)(2)(iv).

Foot-operated brakes must not require more than 70 pounds of applied force to develop the manufacturer’s rated torque, and brakes for stopping trolley or bridge motion must be sized to stop within a distance equal to 10% of full-load speed in feet per minute when traveling at full speed with full load. OSHA sets the foot-force limit in 1910.179(f)(4)(i) and the stopping-distance performance in 1910.179(f)(4)(vii).

Foot-operated brakes must have automatic positive release when pedal pressure is released, and brakes on trolleys and bridges must have ample thermal capacity for the expected frequency of operation to prevent overheating and impairment. OSHA requires automatic release in 1910.179(f)(4)(vi) and adequate thermal capacity in 1910.179(f)(4)(ix).

A trolley brake is required on cab-operated cranes with the cab on the trolley; a bridge brake is required on cab-operated cranes with the cab on the bridge and a holding-type bridge brake is required when the cab is on the trolley; floor, remote and pulpit-operated bridge drives must have noncoasting mechanical drive brakes. OSHA specifies these requirements in 1910.179(f)(5)(i) and 1910.179(f)(6)(i)-(iii).

Control-circuit voltage must not exceed 600 volts (AC or DC), and pendant push-button voltage must not exceed 150 volts AC or 300 volts DC. OSHA sets these voltage limits in 1910.179(g)(1)(ii) and 1910.179(g)(1)(iii).

Pendant control boxes must be constructed to prevent electrical shock and clearly marked for functions, and suspended pushbutton stations using multiple-conductor cable must be supported to protect conductors against strain. OSHA requires pendant box construction and marking in 1910.179(g)(1)(v) and support of suspended stations in 1910.179(g)(1)(iv).

Cranes without spring-return controllers or momentary pushbuttons must have a device that disconnects all motors on power failure and prevents restart until reset or controller is off; lever controllers need an off-position notch or latch (or spring return); controller handles must be within reach, move in directions corresponding to load movement, and controls must be arranged so operators can face direction of travel. Automatic cranes must fail-safe on malfunction and remote-operated cranes must stop motions if control signals become ineffective. OSHA requires these controller and fail-safe features in 1910.179(g)(3)(i)-(iii) and 1910.179(g)(3)(iv)-(ix).

A crane operator must wear a protective helmet when there is a potential for head injury from falling objects, and the employer must provide helmets that meet ANSI Z89.1 consensus standards. OSHA’s head protection rule applies to crane operations with overhead hazards as explained in the OSHA Letter of Interpretation on head protection for crane operators, available at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2, and the protective-helmet standard is 1910.135 (see the Letter of Interpretation for how it applies to cranes).

Under 1910.179(g)(5)(v), cranes using a lifting magnet must have an enclosed magnet circuit switch that can be locked in the open (off) position and a means to discharge the magnet’s inductive load. See 1910.179(g)(5)(v).

• The switch must be of the enclosed type and designed so it can be locked open for servicing or when the magnet is not in use.
• Because magnets store energy, a positive means (such as a resistor or bleed circuit) must be provided to safely discharge the inductive energy when the switch is opened.

This requirement helps prevent unexpected re‑energization and reduces the risk of shock or uncontrolled magnet action during maintenance.

Under 1910.179(g)(6), runway conductors of the open type must be located or guarded so that people entering or leaving the cab or the crane footwalk normally cannot come into contact with them. See 1910.179(g)(6).

• Place conductors out of normal paths where operators step on or off the crane, or install physical guards or covers to prevent accidental contact.
• Design walkways, ladders, and access points so they do not bring workers into reach of exposed conductors under normal access/egress procedures.

This reduces the risk of electric shock or arc hazards during routine crane access.

Under 1910.179(g)(7), any service receptacle provided in the cab or on the bridge of cab‑operated cranes must be a grounded three‑prong permanent receptacle and must not exceed 300 volts. See 1910.179(g)(7).

• Use only grounded (three‑prong) permanent receptacles — not temporary or ungrounded adapters — for powering extension lamps or tools from the crane.
• Ensure wiring and receptacle installation meet the voltage limit (≤300 V) and appropriate electrical safety practices.

This protects operators from shock hazards when using electrical devices mounted on the crane.

Under 1910.179(h)(1)(i)–(iv) and (v), sheave grooves must be smooth and free of defects, sheaves that can be unloaded must have close‑fitting guards to guide the rope back into the groove, bottom‑block sheaves need guards to prevent fouling when lying on the ground, pockets and flanges used with hoist chains must avoid catching, and all running sheaves must have means for lubrication (permanently lubricated sealed or shielded bearings meet this). See 1910.179(h)(1)(i)–(iv) and 1910.179(h)(1)(v).

• Inspect grooves for nicks, sharp edges, or corrosion that could damage rope.
• Provide guards or devices where rope runs free to keep it properly seated when reloaded.
• For hoist chains, design flanges/pockets so chains do not bind or catch during operation.
• Ensure running sheaves can be lubricated or have sealed bearings to maintain safe operation.

Following these items reduces rope/chain damage and prevents failures from poor sheave condition or lubrication.

Under 1910.179(h)(2)(iii)(a)–(b), there must be at least two full wraps of rope remaining on the drum when the hook is in its lowest position, and the rope end must be anchored to the drum by a clamp securely attached to the drum or by a socket arrangement approved by the crane or rope manufacturer. See 1910.179(h)(2)(iii)(a) and 1910.179(h)(2)(iii)(b).

• The two‑wrap minimum prevents the rope from slipping off the drum under load.
• Use the manufacturer‑recommended clamp or an approved socket; do not improvise attachments.

Following the manufacturer’s recommendations for anchoring and maintaining the wrap minimum prevents sudden rope failure and loss of load control.

Under 1910.179(m)(1), running ropes must receive a thorough inspection at least once a month, and a certification record that includes the date of inspection, the signature of the person who performed the inspection, and an identifier for the ropes inspected must be kept on file and readily available to appointed personnel. See 1910.179(m)(1).

• Inspect ropes for conditions that could cause appreciable strength loss (reduced diameter, broken or worn wires, corrosion, kinking, etc.).
• Keep the written certification record with rope ID so inspectors and maintenance staff can track rope condition and replacement history.

Timely inspection and documentation help ensure ropes are removed from service before they become unsafe.

Under 1910.179(j) and 1910.179(k), new or altered cranes must be inspected prior to initial use, cranes in regular service must receive frequent (daily to monthly) and periodic (1 to 12 months) inspections for listed items, and operational tests (hoisting/lowering, trolley and bridge travel, and limit switches/safety devices) must be performed prior to initial use. See 1910.179(j)(1) and (j)(1)(ii) and 1910.179(k)(1)(i).

• Frequent inspections (daily–monthly) include checks for maladjustment, hydraulic leaks, hook defects, hoist chain wear, rope reeving, and other items in 1910.179(j)(2).
• Periodic inspections (1–12 months) are more thorough and include checking for deformed or cracked members, loose bolts, worn sheaves/drums, brake wear, electrical contactor deterioration, and more as listed in 1910.179(j)(3).
• Before initial use, perform operational tests of hoisting and lowering, trolley travel, bridge travel, and limit/locking devices per 1910.179(k)(1)(i).

Keep inspection records where required (e.g., monthly hook and rope certifications) and correct any unsafe condition before returning a crane to service per 1910.179(l)(3)(i).

Note: Employers must also evaluate whether operators and other affected employees need head protection when working near overhead hazards; OSHA’s interpretation on head protection for crane operations explains that helmets are required when there is a potential for head injury from falling objects and references 29 CFR 1910.135. See OSHA’s letter of interpretation on head protection for crane operators at https://www.osha.gov/laws-regs/standardinterpretations/2024-06-06-2.